We are moving in making our third molds for the project. We had serious thickness issues in "thin" areas of the mask (around the cheeks, bottom of the chin and on the back of the skull). These could be patched for a while but would not hold up for regular use and, in that case, myself and my partner decided not to move forward until we had resolved the issue. Thanks to Madog's excellent sculpting skills, we've added more clay and resculpted the thin areas to give us the strength and thickness we needed to start with. Oh well, one learns by trying.....therefore, we tried, and learned and tried and learned....etc.
Given the resculpt has now been done and to improve our process time, we are moving towards a fiberglass mother mold system (dumping the gypsum) and also we have to make a couple of new plugs for our mask. All in all, we are looking towards having a newly designed mask for possible sale sometime in early August. We really only have the weekend to work on this thing, so moving on it quickly is virtually impossible. I work 10 hour days at my job and my partner is often tied up with other projects. I'm just glad some folks are being patient with us. I hope to have some updated pictures soon.
Thanks for asking about it.
Jesse